Emerald t-001

The t-001 was an all-new, lightweight, range-extended electric vehicle (REEV) offering a cost-effective solution with low CO2. The vehicle met the following rigorous requirements:

Capable of up to 106 km (66 miles) range in pure EV mode

CO2 emissions of 40 g/km over first 160 km (100 miles)

640+ km (400+ mile) range and cost per km less than current diesel or petrol vehicles

Medium sized van with payload of 1400 kg and GVW of 3050 kg, developed for the European and US markets

Designed as a SWB Standard Roof and LWB High Roof

Lightweight technologies used in the construction to provide significant benefits over conversions of existing vehicles

Reduction in CO2 with no premium over lifetime costs, compared to a standard vehicle

Advanced PHEV series-hybrid drivetrain with intelligent control

Vehicle Design

The t-001 exterior was designed to demonstrate a highly contemporary style. Quality, durable materials were used to help maintain the vehicle’s appearance throughout its working life. The distinctive lower body mouldings offered visual strength and practical durability for use in the urban environment. Front and rear corner bumpers were designed for easy replacement should damage occur in service.

The interior environment was created to be open and airy with maximum ease of ingress and egress. The interior controls were ergonomically designed around the operator’s needs. All key driver information is displayed via a 7” TFT screen. The rear load space has a 5.2 m3 load capacity and accommodates three Euro Standard Pallets.

Advanced Hybrid Powertrain

The t-001 drivetrain offered the economy and low CO2 benefits of an electric vehicle without the range restrictions. The t-001 could deliver 600 Nm of torque instantly and achieve a top speed of 129 km/h (80 mph). Using the range extender engine, the t-001 achieved 640+ km (400+ miles) on one tank of fuel.

The hybrid control system included a GPS-enabled Electronic Horizon Supervisory Control System that optimised the range-extender engine running to maximise economy and minimise emissions and noise in restricted and urban locations.

The 25 kWh lithium ion battery pack could be recharged from a 3-phase power supply in 2-3 hours. Power from the battery drove a 75 kW electric motor through the rear axle. This gave a range capability of up to 106 km (66 miles) in full electric mode.

When the battery reached a predetermined state of discharge, the on-board range-extending internal combustion engine started and powered the electric motor and recharged the battery. In this mode the total range combining the electric range and one tank of fuel is more than 640 km (400 miles). When the battery reached an adequate state of charge, the range-extender engine switched off and driving continued in all-electric mode. The regenerative braking system also provided charging for the battery, utilising energy that would otherwise be lost.

The t-001 was a series hybrid as the wheels were only powered by the electric motor and the range-extender engine solely ran the on-board generator.

Safety and Durability

The t-001 was developed to achieve the highest possible safety rating in its class. There were low speed crash absorbing structures at the front and rear of the chassis. The chassis had crumple zones front and rear for high speed energy absorption. Roof crush and seat belt anchorage loads were taken by the cab space-frame structure. A special crash structure in the chassis gave side impact protection. Recessed wiper spindles and under-hood clearances aided pedestrian protection. The chassis structure was optimised for crash and strength using advanced CAE techniques.

The t-001 was engineered to meet durability in service requirements as rigorous as a standard internal combustion vehicle. The combined body and chassis structure gave a torsional stiffness of 10,000 kNm per degree.